ES2332633A1 - Procedure for the manufacture of boards of different dimensions with natural stone using as a base a aglomerante and unmortero cement ligante. (Machine-translation by Google Translate, not legally binding) - Google Patents

Abstract

The present invention relates to a method of manufacturing boards, in different thickness and size measurements, taking advantage of any natural stone piece: marble, granite, slate, limestone, quartzite, etc., including artificial stone. These pieces of stone can be rough, or, polished and calibrated. All this set of pieces of stone is placed on a base of a special mixture of cement mortar: mixture composed of white cement, crushed marble or silica or quartz or granite, etc. Adding an accelerant, water repellent, a fluidizer, and acoustic thermal insulation, making boards of different sizes and thickness suitable for placement as a coating both outdoors and inside buildings. The manufacture of these boards is based on the use of all the waste stone generated by the industries of marble, granite, artificial stone and the tailings of the mining areas of stone extraction. Once manufactured these boards are cut to the measures demanded by the market. (Machine-translation by Google Translate, not legally binding)

Description

Procedure for the manufacture of boards different dimensions with natural stone using as a base binder and binder a cement mortar.

Technical sector

The present invention relates to a board manufacturing process, in different sizes of thickness and size, taking advantage of any piece of natural stone (marble, granite, slate, limestone, quartzite or similar) or artificial. These pieces of stone can be rough, or polished and calibrated.

The pieces of stone are placed on a base made with a special mixture of composite cement mortar by white cement, crushed marble, silica, quartz, granite or similar, an accelerator, a hydrophobe, a fluidizer and a thermal and acoustic insulation, allowing the manufacture of boards of different sizes and thickness, suitable for placement as coating both outside and inside of buildings

The manufacture of these boards is based on the use of all the waste stone generated by the Marble, granite, artificial stone reducing industries environmental problems and debris from mining areas of  stone extraction

Once manufactured these boards are cut to the measures demanded by the market.

State of the art

Currently, the placement in stone walls natural: marbles, blackboards, granites, etc., either in exterior, as in the interior, is performed on the wall of a manually placing each stone one by one, of different sizes and leveling one by one on the wall, to get a surface smooth in which they do not stand out from each other, and subsequently Fill the joints with cement. Also if you want give a more striking appearance a varnish is applied to highlight The color of the stone.

This placement technique is quite laborious. because of the fact that you have to select the stone and place one to one leveling it on the wall and sometimes making cuts in the stones before placing them.

The proposed invention consists of a procedure to manufacture boards of different sizes, with the stone already placed in them, perfectly level and calibrated So that the placers will be limited to having the perfectly trained and level wall to place these panels as if they were tiles with the advantage of being a system Quick to install and with little labor, which significantly reduces the costs of execution.

Description of the invention

The proposed invention is a procedure for the manufacture of boards of different sizes and thicknesses with pieces of natural or artificial stone, of different sizes, using a base and binder of a special mortar mixture of cement, which allows to arrange the stone pieces completely leveled and grouting, so that they are placed in the building similar to the tiles of coating. These boards are indicated for coating both exterior and interior of buildings, may have different dimensions according to demand and its placement on site is done with conventional methods of laying stone or tiles natural

The manufacture of these boards includes a initial phase of natural stone selection in different sizes and thicknesses depending on the effect you want to achieve. Then the mixture of the mortar base is prepared cement, which will be composed of white cement without chrome and crushed marble, silica, quartz, granite or similar, in Different grain sizes. Kneading water is added with a setting accelerator, a water repellent and a fluidizer for give the strength and plasticity to the mortar base of cement.

To the cement mixture you can add a dye that improves the finish and imitates the color of the stone that will endure. A thermal insulator is also added and acoustic, which can be made of polyspan balls, polyurethanes, hollow glass spheres, straw cut fiber of origin natural or similar

To give greater resistance to the pieces placed a metal mesh, plastic or similar, of high strength, which will give the board greater resistance to flexion, compression and impact.

The last phase of the process consists in pouring the mix together with the stone strokes on some molds made for that purpose, they can be manufactured in different materials such as iron, latex, silicone, plaster or the like.

Description of the drawings

To complete the description that is being performing and in order to help better compression of the characteristics of the invention, the present specification is attached descriptive with a series of figures that show the following:

Figure 1 - Shows a plan view schematic of the set of elements that make up the boards resulting from the manufacturing process object of the invention.

Figure 2 - Shows an elevation view of the resulting boards with unpolished stone.

Figure 3 - Shows an elevation view of the resulting boards with polished or aged stone.

Detailed description and preferred embodiment of the invention

The procedure for the manufacture of boards of different dimensions object of the invention consists of the phases described below:

one.-

Selection of the type, size, thickness and color of the pieces of stone (1) to be used for the manufacture of boards Once selected the stones will be arranged in the work line.

2.-

Preparation of work molds according to dimensions of the board to be manufactured, according to the market demand.

3.-

Preparation of the cement mortar mixture used for the base of the board (2), which will be constituted by the following elements, in the proportions considered suitable to achieve the appropriate resistance of the board according to its use: white cement without chrome, crushed marble, silica, granite, quartz or similar of different granulometry in function of the finish to be obtained, and kneading water with the following additives:

to.-

Setting accelerator.

b.-

Fluidifier, which allows to reduce the water of kneading and mixing more quickly, increasing the compressive strength and flexo-traction of the mortar, avoiding cracks.

C.-

Water repellent, based on oleates free of chlorides and soluble in water. This product reduces the water absorption of the mortar set and plasticize the dough reducing the capillarity

d.-

Cement dyes, mainly oxides of iron or similar, to achieve the color of cement similar to the stone to place or other tones.

Base formulations of this type of mortar, they could be:

to)

Crushing compound loading mortar marble:

White cement, without chrome

 \ dotl 

25%

Crushed marble 0,05-0,6 mm

 \ dotl 

30%

Crushed marble 0.6-1.2 mm

 \ dotl 

25%

Crushed marble 1.2-2.5 mm

 \ dotl 

twenty%

Over weight of cement:

Setting accelerator

 \ dotl 

2%

Fluidizer

 \ dotl 

2%

Water repellent

 \ dotl 

one%

Dyes, iron oxide

 \ dotl 

3%

The amount of kneading water, will depend on the fluidity that you want to give the mixture.

b)

Crushing compound loading mortar silica:

White cement, without chrome

 \ dotl 

30%

Crushed silica 0.05-0.6 mm

 \ dotl 

25%

Crushed silica 0.6-1.2 mm

 \ dotl 

30%

Crushed silica 1.2-2.5 mm

 \ dotl 

fifteen%

Over weight of cement:

Setting accelerator

 \ dotl 

1.75%

Fluidizer

 \ dotl 

1.8%

Water repellent

 \ dotl 

0.8%

Dyes, iron oxide

 \ dotl 

4%

The amount of kneading water, will depend on the fluidity that you want to give the mixture.

quad

In this phase the mortar mixture to form the base (2) of the board is added an insulator (3), which may be a chemical insulator (adding small polyspan balls, polyurethane, hollow glass spheres or similar), or of type natural vegetable (in the form of cut fiber, such as straw and other vegetable waste).

4.-

The mixture made in the previous phase is poured on the molds prepared for this purpose, which will be placed on vibrating tables to distribute the mortar evenly, in appropriate amount to achieve the desired base thickness (2), which will be a function of the final thickness of the board. On the base, optionally depending on the characteristics resistant to get on the board, you can place a mesh (4), metallic, plastic or similar

quad

These molds with the base already made are taken to a resting area, so that the whole mixture takes consistency and hardness.

5.-

Once the base has the consistency and hardness suitable a new mortar mixture is prepared with the same specifications indicated in phase 2, but without insulation. This new mixture is poured on the molds already prepared with the base and the mesh, in an adequate quantity to achieve the thickness desired, originating a layer (5) into which the pieces of stone (1) leaving a slight joint between them. The pieces of stone will be of different sizes and will cover the entire mold and without leaving large gaps.

6.-

The next process is the grouting of the stones (1) placed in the mold to give the required uniformity to the board. This grouting can be done in two ways, either with white cement, dye and water, with adequate fluidity, to that fills all the gaps, which is the conventional grout. OR well with a more fluid mixture than the cement mortar, it is say with more water, with the same formulation of the base mortar and bonding, but without thermal insulation and with the appropriate dye to The stone to place. These dyes are those indicated for cement, iron oxides mainly.

Once finished grouting, the boards will let stand until dried and then proceed to the cement cleaning of the joints that has stuck to the Pieces of stone placed.

The boards thus finished are allowed to stand so that they take the appropriate resistance and are cut at desired dimensions in a cutting line.

Optionally, before proceeding to cut the boards, they can be treated: varnish protection for graffiti, water-resistant varnish, stone highlight placed, etc.

With this system it is possible to manufacture boards of large dimensions and cut them into smaller formats, according to demand, so that they are supplied as marble tiles, granite, etc., ready to place, saving time and labor that make buildings in which they are used less expensive This type of material.

In addition, the system takes full advantage of waste generated in the extraction and processing industries of natural and artificial stones, marbles, granites, blackboards, artificial stone, etc., reducing environmental problems originated by the waste. The use is almost total, since that takes advantage of the very small size for the mortar of the base, the binder and the cement of the joints, being the crushed coming from stone crushing mills. The most pieces large stone that has not yet been ground and that would pass to rejection are those used for final appearance of the boards finished Even the rejections of the manufacturing factories of polished, aged or other type of stone finish.

Claims (5)

1. Procedure for the manufacture of boards with natural stone, characterized by being constituted by the following elements:

-

A first layer of cement mortar with thermal insulation and acoustic.

-

A mesh to confer mechanical resistance to the assembly, which can be metallic, plastic or similar material.

-

A second layer of cement mortar without thermal insulation and acoustic.

-

A set of natural or artificial stones of different size and thickness.

2. Method of manufacturing boards with natural stone according to claim 1, characterized in that the base is made with a mixture of cement mortar composed of white cement, a compound accelerator, hydrophobe, a fluidizer, an acoustic thermal insulator, as well as a crushed marble, silica, quartz, granite or similar, in the proportions that are considered adequate to achieve the desired strength and finish. 3. Method of manufacturing boards with natural stone according to claims 1 and 2, characterized in that the stone pieces are placed on a layer of mortar mixture of appropriate thickness depending on the final thickness desired on the board, with a composition similar to the mixture used as a base but without acoustic thermal insulation. 4. Process for the manufacture of boards with natural stone according to claims 1 to 3, characterized in that it can incorporate into the mortar mixtures a color that imitates the pieces of stone, or provides a different color, as appropriate. 5. Method of manufacturing boards with natural stone according to claims 1 to 4, characterized in that the outer layer can be treated with a varnish or similar product that gives the assembly additional properties such as a better finish, ease of washing, wear resistance, etc. .